Modular building

ABSTRACT

A modular building unit for construction of a building comprises a structural frame  40  suitable for interconnection to another modular building unit in construction of the building; and a stud frame wall  80/82  internal to and fixed to the frame. The modular building unit is suitable for handling as a shipping container for transport.

The present invention relates to buildings formed of modular units.

BACKGROUND

Buildings formed of recycled intermodal shipping containers, sometimescalled sea containers, are known. However they have not seen mainstreamadoption due to inherent limitations with the use of these containers.It is believed that such buildings are currently based on the premise oftaking one or more shipping containers (generally used) and modifyingthem, such as by removal of side walls and/or end wall or end doorsaccording to the design of the building.

A typical shipping container has standard dimensions: 8 feet wide (2.44m), 20 feet (6.06 m) or 40 feet (12.19 m) long, and 8 feet 6 inches(2.59 m) high. An alternative type, a High-cube (HQ) container is 9 feet6 inches (2.9 m) high. Containers of 10 feet 3 inches (3.12 m) are alsoknown. These containers are designed for carriage on a ship stacked oneon top of another and include a steel casting on each of the eightcorners, pairs of which are welded to either end of each of the fourcorner posts of a rectangular parallelepiped steel frame. Attached tothe frame are side walls, and a roof generally formed of a flat orcorrugated sheet of weather resistant steel or aluminium and have hingeddouble doors on at least one end.

For use in a building, shipping containers require extensivemodification, such as cutting through or removal of the side walls, tobe suited for use in a building so as to allow windows, side entry or adifferent form of doorway. Further they are limited to a width of 2.44 mand a length of 6.06 m or 12.19 m, which in turn limits room sizes tofit within these dimensions.

It is with this background that the present invention has beendeveloped.

Reference to prior art documents is not an admission that they form partof the common general knowledge of a skilled person in any jurisdiction.

SUMMARY OF THE INVENTION

According to the present invention there is provided a modular buildingunit for construction of a building, said modular building unitcomprising: a structural frame suitable for interconnection to anothermodular building unit in construction of the building;

wherein the modular building unit is suitable for handling as a shippingcontainer for transport.

In an embodiment the building unit further comprises a stud frame panelinternal to and fixed to the frame, wherein the frame and panel incombination are load bearing.

In an embodiment the structural frame is in the form of a rectangularprism.

In an embodiment the structural frame is in the form of a rectangulartable shape, comprising a rectangle and four legs, each leg extendingfrom one of the corners of the rectangle. Typically the rectangle willbe at the base of the building unit and the legs will extend vertically.In such a case it will be typical to have another rectangle a structuralframe of another building unit joined at the corners to ends of the legssuch that the other rectangle and the structural frame form arectangular prism.

In an embodiment the panel contributes to the structural capacity of themodular building unit to withstand forces applied to the modularbuilding unit.

In an embodiment the panel coincides with a face of the frame. In anembodiment the panel is set back from a face of the frame.

In an embodiment the panel is or forms part of a wall partly defining aroom at least in part within the modular building unit.

In an embodiment the building unit comprises a plurality of structuralstud frame wall panels internal to and fixed to the frame, the wallsdefining a room within the modular building unit, the plurality ofpanels contributing to the structural capacity of the modular buildingunit to withstand forces applies to the modular building unit. In anembodiment the forces include static forces, such as from other buildingunits stacked on top of the building unit, and from dynamic forces, suchas those experienced in cyclonic weather conditions.

In an embodiment the modular building unit comprises a non-structuralwall panel for forming a partition to a room in the modular buildingunit.

In an embodiment the building unit comprises a veranda deck internal tothe frame, but able to be opened to the exterior of the frame. In anembodiment the veranda deck is open to the exterior of the buildingthrough one of the faces of the building unit.

In an embodiment the veranda deck comprises shutters for closing theveranda deck during inclement weather conditions. In an embodiment theveranda deck comprises a rail or balustrade along one of the faces ofthe building unit.

In an embodiment the veranda deck is open to a veranda deck of anadjacent building unit in use.

In an embodiment a wall partitioning the veranda deck from a room in thebuilding is insulated. In an embodiment an enclosure of the veranda deckis uninsulated.

In an embodiment the building unit further comprises a portion of abuilding-internal service access-way internal to the frame. In anembodiment the building-internal service access-way is covered by aremovable panel for transport. In an embodiment the building-internalservice access-way is open to the exterior of the frame when theremovable panel is removed.

In an embodiment the building unit further comprises a first portion ofa building-internal service access-way able to be externally open on themodular building unit and arranged so that when another building modulewith a complementary second portion of a building-internal serviceaccess-way is placed adjacent the first portion they define a combinedportion of a building-internal service access-way.

In an embodiment the building-internal service access-way is in the formof a recess in a face of the building unit.

In an embodiment the building unit further comprises a weather resistantexternal panel affixed to each side and end face of the frame. In anembodiment the external panels are removable.

In an embodiment the building unit further comprises a removable panelaffixed to a side and/or end face for transport, wherein the panel isformed of FRP.

In an embodiment an air gap is provided between the external panel and awall internal to the frame. In an embodiment the wall internal to theframe is the stud frame panel.

In an embodiment the external panel provides load bearing support to theframe.

In an embodiment the building unit further comprises a plurality ofbeams extending transversely across the bottom of the frame and inwardlyspaced from the ends of the frame for attachment to ground supports oranother building unit.

In an embodiment one or more of the frame or transverse beams are formedof Fibre Reinforced Polymer (FRP).

In an embodiment the building unit further comprises one or moreremovable vertical supports on side faces of the frame.

In an embodiment the unit further comprises one or more removablevertical supports on side faces of the frame, wherein the verticalsupports are formed of a FRP beam.

In an embodiment the internal walls are formed of a stud frame with aninsulating material inside the stud frame.

In an embodiment the building unit further comprises a structural panelinternally affixed to a top face of the frame.

In an embodiment the unit further comprises a panel affixed to a topface of the frame, wherein top panel is formed of FRP.

In an embodiment the building unit further comprises an opening in aside or end face when the removable panel is removed from the respectiveside or face for allowing movement to another building unit in thebuilding.

In an embodiment an external finish is applied to the panels on aside/end of the building unit or ceiling of the unit.

In an embodiment the frame has attachment points at each corner.

In an embodiment the frame has attachment points at each corner formedof FRP.

In an embodiment the building unit is of a width between 2.4 m and 6 mand preferably between 2.6 and 4.2 m. In a preferred embodiment eachcontainer is of a width of about 3.3 m (11′) to 3.5 m.

In an embodiment the building unit is of a length of 6 m (20′). In otherembodiments the container is of a length of one of 6.8 m, 7.2 m, 12 m,14.4 m, 18 m, or 36 m.

In an embodiment the building unit is of a height of 2.9 m (9′6″) to 3.2m. In an embodiment each container is of a height of about 3.48 m. In anembodiment each tall container is of a height of 5.8 m (19′) to 6.2 m.

In an embodiment the building unit is a tall container, where the tallcontainer has a height of two other unit stacked one on another and alength of half the length of other building units. In an embodimentlength is about 3 m. In an embodiment each tall container is of a heightof 8.7 m.

In an embodiment the frame of the container forms a structural elementof a building formed of a plurality of such building units.

In an embodiment the end and or side panels of the container form astructural element of a building formed of a plurality of such buildingunits.

In an embodiment the building unit is configured such that it can beassembled into the building without structural modification.

In an embodiment the building unit is stackable for transport and isable to be stacked in the building.

In an embodiment the building unit comprises a portion of a roof to beplaced above the building unit when the building unit is formed into abuilding.

In an embodiment a truss of the roof portion is formed of FRP. In anembodiment a roof cladding sheet of the roof portion is formed of FRP.In an embodiment the roof portion comprises lifting points.

In an embodiment an opening for receiving a forklift tine comprises acasing form of FRP.

According to the present invention there is provided a modular buildingunit for construction of a building, said modular building unitcomprising a structural frame suitable for interconnection to anothermodular building unit in construction of the building and a wall of thebuilding unit comprises:

a first structural panel internal to and fixed to the frame so as to beparallel with a face of the frame; and

a second structural panel fixed to the frame so as to be parallel to andspaced from the first structural panel so as to provide an air gaptherebetween;

wherein the modular building unit is transportable.

Also according to the present invention there is provided a buildingmodule comprising a roof portion to be placed above the building unitwhen the building unit is formed into a building.

In an embodiment the roof portion comprises a truss formed of FRP.

Also according to the present invention there is provided a buildingcomprising a plurality of modular building units, each modular buildingunit according to one or more of the descriptions above.

In an embodiment the building comprises longitudinally side by sideframes and parallel adjacent back to back internal walls of eachbuilding unit.

In an embodiment the building comprises building-internal serviceaccess-way formed on at least two building-internal service access-wayportions of at least two adjacent building units. In one embodiment thebuilding-internal service access-way portions are formed by the buildingunits being end to end. In one embodiment the building-internal serviceaccess-way portions are formed by the building units are side by side.In one embodiment the building-internal service access-way portions areformed by the building units are end to end and side to side.

Also according to the present invention there is provided a method ofconstructing a building comprising providing a plurality of buildingunits as defined above and placing the building units next to oneanother and connecting the units together into a single structure.

In an embodiment the building units are placed end to end. In anembodiment the building units are placed side by side.

In an embodiment the building units are stacked.

Also according to the present invention there is provided a panel foruse in a building comprising a sheet of FRP having mounting points forfixing the sheet to a structure.

In an embodiment a first surface of the sheet is finished in a mannersuitable for decorative use prior to fixing to a structure.

In this specification the terms “comprising” or “comprises” are usedinclusively and not exclusively or exhaustively.

DESCRIPTION OF DRAWINGS

In order to provide a better understanding of the present inventionpreferred embodiments will now be described, by way of example only,with reference to the accompanying drawings, in which:

FIG. 1 is a schematic set of plan views showing a building unit and abuilding according to an embodiment of the present invention;

FIG. 2A is an upper isometric view of a bank of modular building unitsof the building of FIG. 1, with a roof removed;

FIG. 2B is a lower isometric view of the bank of FIG. 2A;

FIG. 2C is an upper isometric view of a bank of modular building unitsof the building of FIG. 2A, with a removable skin removed;

FIG. 2D is an upper isometric view of a bank of modular building unitsof the building of FIG. 2C, with internal walls being shown in ghostform and with another bank of modular building units adjacent with nointernal walls or roof and a removable skin removed;

FIG. 3 is an upper isometric view of a modular building unit of FIG. 1,with the roof removed;

FIG. 4 is an upper isometric view of a modular building unit of FIG. 3,showing a ceiling and internal walls resulting from a removal ofexternal wall panels;

FIG. 5 is an upper isometric view of a frame of the modular buildingunit of FIG. 3;

FIG. 6 is a partial cross sectioned side elevation of an embodiment of amodular building unit of the present invention;

FIG. 6A is a partial cross sectioned side elevation of an embodiment oftwo modular building units of the present invention stacked one onanother;

FIG. 7 is an enlarged portion of the building unit of FIG. 6;

FIG. 8 is a cross sectioned perspective view of an embodiment of atransverse beam of the building unit according to the present invention,with a removed portion of a floor structure to allow access to thetransverse beam;

FIG. 9 is a horizontal cross section of an embodiment of a corner of thebuilding unit according to the present invention;

FIG. 10 is a horizontal cross section of an embodiment of an internalcorner of the building unit according to the present invention;

FIG. 11 is a vertical cross section of an embodiment of a roof sectionof the building unit according to the present invention;

FIG. 12 is a vertical cross section of an embodiment of a floor sectionof the building unit according to the present invention;

FIG. 13 is a vertical cross section of an embodiment of a wall sectionof the building unit according to the present invention;

FIG. 14 is a vertical cross section of an embodiment of a wall sectionof the building unit according to the present invention;

FIG. 15 is a vertical cross section of an embodiment of a wall sectionof the building unit according to the present invention;

FIG. 16 is a horizontal cross section of an embodiment of a wall sectionthe building unit having a window of according to the present invention;

FIG. 17 is an end view of a cluster of the building of FIG. 1;

FIG. 18 is a side elevation of the cluster of the building of FIG. 6;

FIG. 19 is a side elevation of a pair of panels according to anembodiment of another aspect of the present invention;

FIG. 20 is a side elevation of an end of a modular building unitaccording to an embodiment of another aspect of the present invention;

FIG. 20A is a side elevation of an end of an alternative modularbuilding unit according to an embodiment of another aspect of thepresent invention;

FIG. 21 is a side elevation of a side of the modular building unit ofFIG. 20;

FIG. 21 A is a side elevation of a side of the modular building unit ofFIG. 20A;

FIG. 22 is an upper isometric view of a bank of modular building unitsaccording to an embodiment of the present invention;

FIG. 23 horizontal cross-sectional plan view of the bank of FIG. 22;

FIG. 24 horizontal cross-sectional plan view of a modular building unitaccording to an embodiment of the present invention;

FIG. 25 horizontal cross-sectional plan view of a portion of a buildingcomprising a plurality of building units of FIG. 24;

FIG. 26 is a side elevation of the building unit of FIG. 24;

FIG. 27 is an end view of the building unit of FIG. 25;

FIG. 28 is an enlarged horizontal cross-section of detail D1 of FIG. 24;

FIG. 29 is an enlarged horizontal cross-section of detail D2 of FIG. 24;

FIG. 29A is an enlarged horizontal cross-section of detail D4 of FIG.24;

FIG. 29B is an enlarged horizontal cross-section of an alternativedetail D4 of FIG. 24;

FIG. 30 is an enlarged horizontal cross-section of detail D3 of FIG. 24;

FIG. 30A is an enlarged horizontal cross-section of an alternativedetail D3 of FIG. 24;

FIG. 31 is a schematic plan view showing portions of an embodiment of aroof of a build according to the present invention;

FIG. 32 is a schematic upper isometric of a building unit according tothe present invention;

FIG. 33 is a plan view of a selection palette of types of modularbuilding unit according to the present invention; and

FIG. 34 is a schematic set of isometric views showing alternativebuilding configurations according to an embodiment of the presentinvention.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIG. 1 there is shown a building 10 according to anembodiment of the present invention. The building may be for example amine site accommodation village, a hotel, hospice or offices.

The building 10 comprises one or more clusters 12. In this embodiment acluster comprises a plurality of similar usage areas. For example in anaccommodation complex a living quarters may comprise usage areas thatmay be bed and bath rooms. The cluster comprises a plurality of banks14, 14′, 14″, 14′″ of modules. A bank 14 of modules comprises one ormore modular building units 16. In this embodiment every unit in thebank, and preferably in the cluster, has the same dimensions. In thisembodiment each bank 14 comprises three units 16 positioned end to end.Thus each bank has the same dimensions. In an alternative embodiment(such as is shown in FIGS. 22 and 23) the bank comprises two units endto end. In yet a further embodiment the bank is a single building unit(such as is shown in FIG. 24).

Further in this embodiment each bank 14 comprises a mirrored usage areaon each side of a corridor 30. For example each bank 14 may compriseliving quarters on each side of the corridor 30. In an alternative or inaddition a bank 14 may comprise a plurality of units 16 side by side. Inthis embodiment each cluster comprises a plurality of (in this casefifteen) banks 14 in a side by side arrangement. Further the cluster 12comprises different types of banks 14′, 14″ and 14′″, each with adifferent usage, on either side of the plurality of banks 14. In thisembodiment the banks 14′ comprises a vertical access unit, such as astair way or elevator. In this embodiment the clusters are offset andconnected to each other by a cluster connection portion 20.

In an embodiment each unit is of a unit type and each unit is configuredaccording to its unit type. In an embodiment the configuration comprisesone or both of internal wall configuration and external (perimeter ofthe unit) wall configuration. In an embodiment each bank is of a banktype, where each bank type is defined according to the unit types of itsunits.

A bank 14 is shown in more detail in FIGS. 2A to 2D. In this embodimentthe bank 14 comprises unit 16A, which comprises a service corridor 30and service entries to bathrooms 32 and 32′. On either end of unit 16Ais units 16B and 16C, each of these comprise a bedroom 34/34′ andveranda or private balconies 36/36′. A doorway 56 leads from room 34′ tothe bathroom 32′. In an alternative the corridor may be a hallwaycorridor and rooms 32 and 32′ are entries and rooms 36 and 36′ arebathrooms.

Also referring to FIGS. 3 to 5, each unit 16 comprises a structuralframe 40 in the shape of a rectangular prism. In an alternative form thestructural frame 40 is in the form of a rectangular table shape,comprising a rectangle and four legs, each extending from one of thecorners of the rectangle. Typically the rectangle will be at the base ofthe building unit and the legs will extend vertically. In such a case itwill be typical to have another rectangle of another building unitjoined at the corners such that the other rectangle and the structuralframe form a rectangular prism.

Typically the frame 40 is formed of steel beams, however in anembodiment the frame 40 is formed of Fibre-Reinforced Polymer (FRP)(also known as Fibre-reinforced plastic) beams fixed together by bondingand or mechanical coupling.

FRP is a composite material formed by reinforcing a polymer matrix withfibres, typically glass fibres (fibreglass) or carbon fibre or aramidfibre. The polymer is typically a thermoset or thermoplastic resin. Thefibres are generally oriented to provide strength and deformationresistance as required by the member formed of FRP. In the case of abeam the fibres are oriented for load bearing and resistance tolongitudinal deformation. FRP beams are connected to form the frame byremoving any residual mould release agent on the site of the connectionpoint, applying a structural adhesive and or fixing with a mechanicalcoupling, such as bolting the beams together or to a common connectionmember, such as a corner 50.

The inside of the prism 56 will be a portion of the inside of thebuilding, when constructed. Longitudinally disposed end faces of theframe have vertically extending support members 44. In an embodiment thesupport members 44 are formed of steel, however in an alternativeembodiment they may be formed of FRP beams. The longitudinal framemembers have removable supports 52 extending vertically between them,which are used during transport of the unit and may be retained insuitable positions to provide additional support strength to thestructure. However these supports 52 may also be removed leaving openthe space 46 between the top and bottom longitudinal frame members. Thisenables an area in the building to be larger than would otherwise beavailable when the walls are removed leaving open space 46 leading tothe inside 56 of the unit 16. A bottom face of the frame has transversesupport members 42 in the form of beams. The top face of the frame mayalso have transverse support members. The support members 42 allow thefloor of the unit to support sufficient weight and can also be used tomount a bottom level to a ground support/mounting system or to a levelof units beneath. Transverse members 70 extend between the longitudinalhorizontal bottom frame members 40 and support a floor 86.

For transport, and if desired to be used in the assembled building, thefaces of the prism may have outer side walls 60 and end walls 62, asseen in FIG. 3. In one embodiment an internal side wall 80 and or aninternal transverse wall 82 are provided inside of an outer wall andinside of the frame 40, seen in FIG. 4. Outer walls 60 and 62 are notshown and frame 40 is ghosted in FIG. 4 so that the internal walls 80and 82 can be more clearly seen.

In an embodiment the internal walls 80/82 may be configured as requiredto define a room or rooms or part of a larger room in the unit. Theouter wall 60/62 is a skin preferably suitable for transport of the unitin a weather exposed condition. In an embodiment the outer wall 60/62 isformed of one or more panels of weathering steel, such as Cor-Ten™ or inan alternative form of FRP. In an embodiment the outer wall 60/62 isremovable after transport or retained as a weather resistant outer wallin the building or as a structural member fixed to and supporting theload bearing capacity of the frame. The internal wall 80/82 (shown inFIG. 6 with the side wall 60 not shown) may also provide structuralintegrity to the unit 16, particularly to support loads in combinationwith the frame when used in a multi-storey configuration or when used incyclone prone areas. In this embodiment the internal wall 82 is behindend walls 62. The units 16 may also have an internal ceiling 84 and atop surface skin 64 comprised of the same whether resistance material asthe side wall 60 for transport. This may also be retained in thebuilding 10.

The external skin 60/62 and or internal walls 80/82 may be formed of apanel comprising a sheet of FRP finished with a decorative appearance ona surface prior to installation in the unit, such that the surface willbe displayed when installed in the unit. Such a panel will haveapplication in buildings other than in the modular building unitdescribed herein. The panels will have securing points, such as holes,for bolting or screwing to the frame or other structure of the building.

For transport the corners 50 of the unit 16 may have attachment pointsfor lifting the unit to and from a transport vehicle, such as a truck,rail car, or ship, and for positioning in place in the building 10. Theattachment points are in the normal form of “castings” using forshipping containers, although in an embodiment these are formed of FRPand may be integrally formed with the vertical edge members of the frame40 or the longitudinal members of the frame 40. In the sides of thelower longitudinal frame members 40 there are fork pockets 54 forreceiving tines of a forklift, the same as is a normal shippingcontainer.

Transverse dashed lines II and HH extend through the beams 42. Theyintersect at 48 with longitudinal dashed lines I and H. These linesallow a grid to be used in the design of the building and are spaced ¼of the width/length of the unit in from the edge of the unit. In thisembodiment they extend through the intersection of vertical supports 44with the end bottom structural members 40. In an embodiment the verticalsupports are about 2.4 m apart. They are also removable to allow a clearopening 47. Generally the opening 47 will be internal to the building,with loads distributed to and through the frame and in some cases thestructural wall panels 80/82 and panels 60/62.

The beams 42 are positioned inwardly of the respective ends of the frame40, ideally about a third to a quarter of the length of the frame 40.The beams 42 should be positioned outwardly of the fork pockets 54,which are generally about 2 m apart.

The vertical supports 44 are positioned inwardly of the edges of theframe 40, ideally about a quarter of the width of the frame 40. In anembodiment the supports 44 are about 0.5 to 1 m and preferably about0.486 m from each edge.

The vertical supports 52 are positioned inwardly of the edges of theframe 40, ideally about a quarter to a third of the length of the frame40. In an embodiment the supports 52 are about 2 m from each edge. Eachof the supports 52 need not be positioned inwardly from the edge by thesame distance. This is the case in FIG. 5. They may be positioned toprovide a structure to fix internal walls to.

In an embodiment a diagonal brace may be provided on the side faces ofthe frame 40 for transport. Such bracing may also be used in theinternal walls 80/82 and ceiling panels in the roof 84 and in the floor86.

In an embodiment a portion of or the whole of the building ismultistorey. In the embodiment shown in FIGS. 17 and 18 there are twostories. As shown, banks 14A, 14B and 14C each have respective banks14AA, 14BB and 14CC on top so that there are two storeys. Bank 14A hasend corridor unit 16A with a door to the exterior of the building or toan access-way in bank 14A prior to lower stair well units 16BA and16BA′. Above unit 16A in bank 14AA is an end corridor unit 16AB with adoor to the exterior of the building and a hand rail. A top part of thestair well units 16BA and 16BA′ is in bank 14AA. A unit may be twostoreys high. A roof is in two parts 100 and 100′ and spans bank 14AA.Each part 100 and 100′ is longer than the respective end building unitand partly covered unit 16AB.

Referring to FIG. 6 an embodiment of a building unit is shown mounted tofootings 150, 152 and 154. In an alternative a slab may be used as wellas or instead of the footings. The transverse beams 42 are inward of theends of the building unit and are fastened to inner footings 150, thebottom attachment points 50 on the exterior are fastened to perimeterfooting 152 and the bottom attachment points 50 on the interior of thebuilding, along with the attachment points 50′ of an adjacent buildingunit are fastened to footing 152 by two C channels. In an embodiment thefootings 150, 152 and 152 are pile footings above ground level. In analternative they may be at or below ground and in a further alternative,instead of footings there may be vertical posts or screw piles. In yet afurther alternative, instead of footings there may be attachment pointsto a building unit underneath, as shown in FIG. 6A. It is desirable forthe beams 42 have a suitable flanged surface with a hole or holestherethrough to be bolted in place.

There may be correspondingly positioned beams 42′ on the top face of theframe for attachment of beams 42 in a building unit stacked on top.Beams 42 and 42′ may provide structural reinforcement of the frame,including resistance to torsion through the length of the building unit.

It can be seen in FIG. 6A that the corner attachment points 50 betweenthe stacked units sit on the other and are able to be fastened together.Further the transverse beams 42 in the upper unit are able to sit on thelongitudinal members of the frame 40 and/or other longitudinal channelmembers 88 (such as C channels) fastened to the frame 40. In anembodiment the members 88 may be formed of FRP.

In this embodiment the building unit has spaced apart oppositelydirected monopitch-like roof part 100 fastened to top longitudinalmembers of the frame 40 and/or other the longitudinal channel members88. The roof part comprises abutting roof portions 102, 104, 106 and 108with an overlap 124 in a top drainage sheet 114. There may be otherportions not shown in FIG. 6. Each portion may be progressively longerin a horizontal dimension than the previous and shorter in height thanthe previous. In an embodiment the width (into the page) of the roofportions is smaller than the width of each building unit. In anembodiment each roof portion is ½ or ⅓ the width of the building unit,such that 2 or 3 panels of the same type sit side by side on the topwall 64 to cover the width of the building unit.

Referring to FIG. 7, in an embodiment, the roof portions are formed of asloping truss or frame with a bottom horizontal beam 118 being a joist,a top horizontal beam 110 being a rafter and S-shaped sections 112 beingbattens onto which is fastened a roof sheet 114. There are verticalbeams 120 at the end of each truss, which abut between adjacent portionsand may be fastened together. It can be seen that the taller portion 102has its roof sheet 122 overlap sheet 114 at 124 to ensure properprogressive run-off of water from the roof 100. In an embodiment theroof portions or parts thereof, including the beams 110, 118, 120, 116of the truss and roof sheet 114 are formed of, for example, extrudedaluminium and steel roof sheets or FRP beams/panels or as an integrallymoulded FRP member.

Also shown in FIG. 7 an insulated wall 80 has service conduit 182installed for use by electrical cables or plumbing services. In analternative or in addition service access skirting may be providedbetween the inner wall 80 and the floor structure 86.

Referring to FIG. 8, the transverse beam 42 is shown in more detail. Thebeam is an I beam in one embodiment or two back to back C channels inanother embodiment. The beam 42 is preferably welded, bonded and ormechanically coupled (such as by bolting) to the longitudinal bottomframe member 40. The beam 42 has fastening holes 130 for fastening thebeam 42 to the footings 152, or to another building unit beneath. Alsoshown are transverse C channel cross members 70 extending between thelongitudinal horizontal bottom frame members 40. In an embodiment thecross members are formed of steel or FRP. Also shown are floor member(s)132 which form a floor 86. An access panel covering a fixing point ofthe beam 42 is removed. Fixing the beam 42 to footings allows transferof load from the frame to footings additional to those at each end.

Referring to FIG. 9, a corner of the building unit showing an insulatedinternal wall 80 is shown joined to internal wall 82. The wall 80 iscomprised of a frame, such as a light steel frame 160 with an insulatingmaterial 164 in between panels of magnesium oxide cement board orplasterboard, FRP panels or the like. The wall may be certified forcyclonic conditions and or may be fire retardant. Thermal-break sheets166 and 168 may be provided on either side of the frame 80. A lightsteel vertical member 170 sits within the frame 160 inside the cornerpost 40 such that a gap 172 is provided between the internal wall 80 andthe side wall 60′ and end wall 62. The member 170 is also fastened tothe longitudinal frame members and if applicable the vertical members52. The internal wall 80 has vertically extending steel studs regularlyspaced along its length. A typical example spacing is 300 mm. A lining182, such as wall paper, or laminate may be applied to an internal wallcladding 174, which in turn may be applied to a water resistant sheet176 for wet areas, such as bathroom or laundry. Variations to the wallstructure are described in relation to FIGS. 13 to 16.

The walls 80/82 may be constructed in a manner that would enable them toreceive a cyclone resistant rating as if they were not to be inside theframe. This enable the building unit to have the structural integrity ofa cyclone rated structure internal to the frame, notwithstanding theincreased structural integrity provided by the frame and or the wall60/62.

Also shown there is a connector 190 connecting the connection points 50of corner post 40 and a corner post 40′ of another building unit.

The wall member 60A in this embodiment is different to the wall member60 in other embodiments. It has columns 332 recesses for receivingfixing members 184 and holes 186 for attachment of an aesthetic externalcladding 232. The wall 60A may be bolted to the frame 40 by bolt 188.The external cladding may be a sheet of FRP.

FIG. 10 shows a similar structure at a corner of four units. There is anair gap 192 between wall members 60 and 60′. When adjacent wall members60 or 62 are removed the air gap 192 may be used for services.

Referring to FIG. 11, there is an embodiment of a ceiling structure 84comprising a top panel 64, which is typically formed of a weatheringsteel or an may be formed of a FRP panel. In an embodiment, underneathis an internal insulating ceiling panel 208, preferably separated by anair gap. In an embodiment this ceiling panel is formed of a stud framewith thermal insulating material between the frame studs, where requiredservice ducts or conduits are provided. The ceiling panel is typicallyfixed to the frame and increases the structural integrity of the frame.In an embodiment on one or both sides of the stud frame is a sheet ofinsulating material, such as an air-cell aluminium foil 206 and 210,which acts as a thermal break. In an embodiment underneath the panel 208is a decorative cladding 212, which is typically fire proof, such asmagnesium oxide cement panels, or a FRP panel. The panel 212 may beacoustically dampening, by for example being provided with soundcancelling perforations.

In an alternative to decorative cladding 212 there may be battens for asuspended ceiling.

In an embodiment on the roof there is a profiled sheet metal panel 202on hinges which is held by brackets at an optimal angle so as to supporta solar panel 204. Alternatively a solar panel may form part of a roofpanel.

Referring to FIG. 12, there is an embodiment of a floor structure 86comprising a bottom panel 132, which is typically formed of weatheringsteel or a FRP panel fastened to the cross members 70. In an embodiment,on top of this is a sheet of waterproof insulating material, such as anair-cell aluminium foil 222, which acts as a thermal break. In anembodiment on top of this is a metal insulated panel 224, such as a 50mm polystyrene core with 0.5 mm powder coated sheet metal on each sideor concrete waffle beams. On top of this is a Compressed VinylComposition floor 226. Other floor surfaces may be used as alternatives,such as tiles, wood or carpet.

Referring to FIG. 13, an embodiment of an external wall 230 of thebuilding is shown. In this embodiment an optional external cladding 232is applied to the external side of a panel 60A or end 62A, such as byuse of the fixing members 184 and holes 186. On the internal side is aninsulating wall panel 236, such as panel 80. In an embodiment the panelis formed of a stud frame with thermal insulating material 252 betweenthe frame studs 250. Where required, service ducts or conduits areprovided in the panel 236. In an embodiment on one or both sides of thestud frame is a sheet of waterproof insulating material, such as anair-cell aluminium foil 234 and 238, which acts as a thermal break. Inan embodiment on the inside surface is a decorative cladding 240, whichis preferably fire-proof, such as a magnesium oxide cement board or anFRP panel. This cladding may have a decorative image applied to thedisplayed surface.

The panel 236 has a bottom edge 254, which sits on the bottomlongitudinal member of the frame 40. The cladding 232 and side/end 60/62extend down further as they cover the full side of the building unit 16.

Referring to FIG. 14, an embodiment of an internal wall 240 of thebuilding is shown. This wall will be on the exterior of a building unit,but will become an internal wall of the building when the building isassembled form the building units. It has a similar construction to wall230 except that the cladding 232 is not included. Optionally side/end60/62 may be removed. Typically this internal wall 240 will face asimilar mirrored internal wall of the adjacent building unit.

Referring to FIG. 15, an embodiment of an internal wall 260 for a“wet-area” is shown. A wet area is an area that has water services, suchas bathroom, laundry, outdoor barbeque area or kitchen. It has a similarconstruction to wall 230 except that the cladding 232 is optionally notincluded. Optionally side/end 60/62 may be removed. In addition there isa water resistant cladding 262 on the inside most surface. This cladding262 may be a FRP panel.

Referring to FIG. 16, an embodiment of an internal wall 270 with anopening is shown. It has a similar construction to wall 260 except thatan opening 56 is provided in the wall, which may have a door or a window274. In an embodiment the window is a powder coated or vinyl wrappeddouble glazed sliding window with thermal break frame 272. In anembodiment this wall section may be used a wall to a veranda area. In analternative this wall 270 may be an external wall, in which case theside/end wall 60/62 may be present, and optionally external cladding 232may be included if it is exposed to the outside atmosphere. The externalcladding 232 may be a weathering steel or FRP panel 60/62 and may have adecorative finish applied to the displayed surface.

It is preferred that the insulation material is fire resistant, such asfor example stone/rock wool insulation, although other layers, such asthe sheet/skin 60/62, or the magnesium oxide cement board 212/238 alsoserve as a fire resistant layer. It is also preferred that this layeralso have water and mould resistance properties and acoustic insulatingproperties.

The opening 56 may have a cyclone rated shutter installed, which wheninstalled with wall 62 in the opening from the veranda to the exteriorof the building 10, allows the veranda, which is internal to the frame40 to become cyclone rated.

In an embodiment the veranda deck comprises a rail or balustrade alongone of the faces of the building unit.

In an embodiment the veranda deck is open to a veranda deck of anadjacent building unit in use.

In an embodiment a wall partitioning the veranda deck from a room in thebuilding is insulated. In an embodiment an enclosure of the veranda deckis uninsulated.

The internal walls 80/82, ceiling panel 208 and floor structure 86,excluding bottom panel 132, may be constructed, with services installed,as one or more internal modules, which are in turn installed in andfixed to the frame 40.

The internal walls 80/82, internal ceiling panels 208 and floorstructure 86, excluding bottom panel 132, may in a box structure havinga suitable structural integrity as if the frame 40 were not present.This may allow for the building unit 16 to have a weather rating atleast equivalent to the rating the equivalent structure would havewithout the frame 40.

For ease of transport, advantageously the rectangular parallelepipedstructural frame 40, with the walls 60 and 62, can be handled as ashipping container. More advantageously the frame can be overwidth,wherein the width of the frame is of at least 2.4, preferably 2.6 m to4.2 m, more preferably about 3.3 m (11′) to 3.5 m and most preferably3.4 m.

In an embodiment the length of the frame is about 6 m, 6.8 m, 7.2 m, 12m, 14.4 m, 18 m or 36 m. In an embodiment the height of the frame is thesize of a HQ container, which is about 2.9 m in height. In an embodimenta tall container is of a height of 5.8 m (19′). In an embodiment eachcontainer is of a height of about 3.12 m or 3.48 m. In an embodimenteach tall container is of a height of 6.24 m, 6.96 m or 8.7 m.

The air cavity between the external wall 60/62 and the internal wall80/82 means that the external walls of container may not need to betotally waterproof and the external walls 60/62 can be bolted, (or ifsteel spot welded) for cost savings. Further the units do not needing togo into a floatation tank to see if they are totally waterproof. Thereis also the flexibility of optionally removing the exterior wall 60/62on location according to the design if the building, a well as, futurereplacement if transported again. It is desired that the top exteriorpanel 64 be waterproof for transport.

Referring to FIG. 19 there are a pair of side by side panels 980 formingat least a part of an internal wall of a building, or an externalcladding. Each panel 980 is comprises a sheet of FRP finished with adecorative appearance, eg a coloured wall. In an alternative thefinished appearance may comprise a photograph, a picture, an artwork oran image, such that the surface will be displayed when installed in thebuilding. The finish is applied to the panel prior to installation onthe wall. The panels have securing points, in form of holes 982, forbolting or screwing to the frame or other structure of the building.Alternatively the panels may be secured with an adhesive or bondingagent such as a resin. This panel 980 may be used as panel 238 in theprevious aspect of the invention.

Referring to FIGS. 20 and 21, building unit comprises an external skin960 in the form of a panel comprising a sheet of FRP. The panel isfinished with a decorative appearance, eg a brick pattern, or in thiscase, by example only, a hexagonal pattern, such that the surface can bedisplayed when installed on the building. The panels are securing bybolting or screwing the panel through corner holes 962 to the frame orother structure of the building, or by adhesion. FIGS. 20A and 21A showan alternative where the external skin 960 covers the frame 40.

In an embodiment the modular units are configured such that they can beassembled into the building without structural modification.

Building units can be affixed by each other by the frame and the frametransfers loads to the ground/footings. The wall panels in effectreinforce the frame, assist in load transfer.

Referring to FIG. 22, an alternative bank 414 is shown. In essence thisbank 414 is substantially the same as the bank 14 described above,except that in this embodiment the bank comprises two end to endelongate modular building units 16′. Also in this embodiment thecorridor 30 is replaced by an internal service access-way 30′, which maybe narrower than corridor 30 and may be walled so that access is onlyavailable from above or below, or through a service panel in room32/32′. The units 16′ each comprise a deck for the veranda 36, which isinternal to the frame 40, a bedroom 34 and a bathroom 32. The veranda 36is open to the exterior of the building. The service access-way 30allows service access to the bathrooms 32 of each unit 16′. Each unit isa discrete dwelling.

FIGS. 24 to 27 show a further alternative embodiment. In this embodimentthe bank 14 is comprises of a single modular building unit 16″ and theunits 16″ are arranged side by side as shown in FIG. 25. In essence thisunit 16″ is substantially the same as the bank 14 described above,except that in this embodiment the unit 16″ has a longer frame 40 and isdivided into two dwellings. There is no corridor 30. This is replacedwith an internal service access-way 332 which is made of two partaccess-way portions 330 and 330′ set on complementary sides of adjacentunits 16″. This form of access-way can by used in the two unit bankembodiment by having each back contribute a portion of the space thatmakes the service access-way 332.

Again each dwelling of the unit 16″ comprises a deck for the veranda 36,which is internal to the frame 40, a bedroom 34 and a bathroom 32, withthe bathrooms being adjacent each other and the services are providedvia the service access-way 332. Panel portions 360, 362 and 364 may beremoved with the panels 60/62 or separately to allow access to theverandas 36 and the service access-way portion 330.

Having a wet area and a “dry area” in the one module becomes possible,such as a bathroom 32 and living room 34 (and veranda 36) in the samemodular building unit.

It can be seen that in the above embodiments the modular building unitcomprises: a rectangular parallelepiped structural frame 40 suitable forinterconnection to another modular building unit in construction of thebuilding 10, whether in a bank of one unit or in a bank or two or threeunits. The internal structural stud frame wall 80/82 is fixed to theframe 40, and defines rooms within the modular building unit. Theexternal weather resistant panels 60/62 are affixed to a side and/or endface of the frame 40 and may be removed. The service access-way30/30′/332 is internal to the frame. It may be covered by the removablepanel 60/62 for transport and open to the exterior of the frame when theremovable panel 60/62 is removed.

Due to the verandas 36/36′ being inside the frame 40, they may beprotected from the weather, for example by shutters and or by having aroof, which can allow the wall to the room 34/34′ to have glazing.

FIG. 28 shows a detailed horizontal cross-section of D1. The air gap 172between the external panel 62 and the stub wall 82 is clearly shown.

FIG. 29 shows a detailed horizontal cross-section of D2. Thermal breakframe 272 for glassing is shown.

FIG. 30 shows access-way portion 330 in detail D3, where the wallsection is the same as 250.

FIG. 30A shows and alternative to the detail of FIG. 30, in whichcolumns 332 are present for attachment of external cladding 232, wherethe wall section is the same as 230.

FIG. 29A shows an opening 302 from detail D4. There is a balustrade orhand rail 304 for providing a safety barrier when the veranda is atheight. There is a temporary cover 308, such as of plywood duringtransport.

FIG. 29B shows an alternative opening 302 with a door 320 to the detailD4. There is a balustrade or hand rail 304 for providing a safetybarrier when the veranda is at height. There is a temporary cover 308,such as of plywood during transport.

FIG. 31 shows an example of how a roof part 100 (and 100′) may bedivided longitudinally into thirds, such that for example portion 108 isdivided into roof components R22, R26 and R30. Other forms of roof maybe used or an open air corridor may be provided. In an embodiment C1, C2and C3 are open air.

FIG. 32, which is a schematic representation, shows the fittings 280 ofthe modular unit 16 in place or ready to final fitting prior totransport to site and packaged furnishings inside 56 the unit fortransport to site. In particular the roof sections are contained in theunit for transport to site and then assembly. It is desirable that eachmodular unit contains its own roof components, in this case roofcomponents R22, R26 and R30 of roof portion 108 are show by way ofexample.

Referring to FIG. 33 a plurality, in this example 12, different types ofunit can be available as stock units, which are prefabricated withfittings, including, external walls, internal walls, doors, and otherfittings, such as for example bathroom fittings, kitchen fittings,laundry fittings, lighting, wiring, and plumbing. The wiring andplumbing may be installed on-site or may be ready for connection toother units or externally. Fittings such as lights, taps, airconditioning etc may be installed on site or may be in finished form.This allows the building architect to modularly design the building,order the desired units, ship them to site and assemble to building.

In FIG. 33 each of the types of unit is, by way of example:

-   -   1—carport;    -   2—alfresco area;    -   3—living room;    -   4—dining room with kitchen bench;    -   5—study or bedroom with veranda;    -   6—bathroom/laundry with veranda;    -   7—bathroom/laundry with passage;    -   8—bedroom with bathroom;    -   9—meals room with kitchen;    -   10—alfresco with barbeque area;    -   11—entry veranda with stairs; and    -   12—stairs entry and living/bedroom area.

In this example, plain white areas may have a concrete floor, verticallinear shading may be a timber or similar floor, dotted areas are “dryareas” floors with furniture and square pattern is a “wet area” withcabinetry and fittings floor.

Internal walls and doors may be of a standard type, such as light steelstud wall supporting spaced apart panels or polycarbonate insulatedpanels. A door frame may be installed in the wall frame with additionalsupporting vertical studs.

FIG. 34 shows an assembly process where a modular unit is in containerform for transport. Once it arrives on site, it may be ready forassembly in place, or one or more external skins (60/62/64) may beremoved as shown in the examples. Walls 60A and 62A may have preparationfor site fixing of cladding. Some units may be taller than others, suchas in the case of stair wells or elevator shafts. The modular units arethen placed into banks, side by side or end to end and the banks formedinto the building, including in some embodiments stacking of the units.The internal structure of the modular unit, which allows it to bestacked for transport and also allows it to be stacked in constructionof the building. When adjacent units have the skins 60 removed, as wellas support members 52 to create a larger open area, additional bracingmay be employed in the other walls of the unit or in surrounding unitsto compensate to the removal of the support members or ceiling. Inaddition or instead corner braces may be employed for structuralstrengthening.

Further it is desirable to have the vertical support in the nearestadjacent wall retained (not removed), that is the nearest verticalsupport connected via the nearest intersection 48 to retain structuralintegrity of the unit.

The transportability of the units may also be useful not just toconstruct a building, but also to move the building to a differentlocation, or to break up the building and reuse the modular units on oneor more other buildings of different design.

The present invention may have particular advantages where the buildingis in a remote location and there are significant transportation costsinvolved in construction of the building and or where labour costs aresignificant as it is desirable to minimise the on-site constructioncosts. However application of the invention is not limited to remotelocations.

Modifications may be made to the present invention with the context ofthat described and shown in the drawings. Such modifications areintended to form part of the invention described in this specification.

The invention claimed is:
 1. A modular building unit for construction ofa building, said modular building unit comprising: a structural framesuitable for interconnection to another modular building unit inconstruction of the building, wherein the modular building unit isadapted to be transported as a shipping container; and a stud framepanel internal to and inwardly spaced from a parallel adjacent externalface of a portion of the structural frame, wherein the stud frame panelcomprises a panel frame, which is distinct from the structural frame anda plurality of vertically extending studs, wherein the panel frame andthe vertically extending studs in combination configure the stud framepanel to be structurally load bearing; wherein the stud frame panel isdirectly and immovably fastened to the portion of the structural frameso as to be load bearing in combination with the structural frame.
 2. Amodular building unit according to claim 1, wherein the building unitcomprises a veranda deck internal to the structural frame, wherein theveranda deck comprises a hurricane resistant shutter able to be openedso as to open the veranda deck to the exterior of the frame and able tobe closed so as to close the veranda deck from the exterior of theframe, wherein the veranda deck has an opening and is able to beconnected to an adjacent veranda deck of an adjacent other building unitwhen the building is assembled so as to allow passage between theadjacent veranda decks.
 3. A modular building unit according to claim 1,wherein the building unit further comprises a portion of abuilding-internal service access-way that is internal to a side or endface of the structural frame, and extends vertically in height betweenhorizontal members of the structural frame of the building unit, whereinthe portion of the building-internal service access-way is exposed tothe exterior side or end of the building unit and is configured tocooperate with another building-internal vertically extending serviceaccess-way portion that is internal to a frame of an adjacent othermodular building unit, such that when the modular building unit isco-operating with the adjacent other modular building unit there isformed the building-internal service access-way, such that thebuilding-internal service access-way extends between the modularbuilding unit and the adjacent other building unit and thebuilding-internal service access-way has a height that extendsvertically between the horizontal members of the structural frame,wherein the portion of the building-internal service access-way is sizedso that the building-internal service access-way formed fromco-operation between the portion of the building-internal serviceaccess-way and the other building-internal vertically extending serviceaccess-way portion permits entry of a person therein.
 4. A modularbuilding unit according to claim 1, wherein the building unit furthercomprises a weather resistant removable external panel affixed to eachside and end face of the structural frame and is in-line with thecorresponding side or end face of the structural frame, wherein theweather resistant removable external panel covers the stud frame panelwhen the weather resistant removable external panel is in place.
 5. Amodular building unit according to claim 4, wherein an air gap isprovided between the weather resistant removable external panel and thestud frame panel such that there is a horizontal offset between aninnermost face of the weather resistant removable external frame and anexternal face of the stud frame panel.
 6. A modular building unitaccording to claim 4, wherein the weather resistant removable externalpanel is configured to support the load bearing capacity of thestructural frame when the weather resistant removable external panel isin place.
 7. A modular building unit according to claim 1, wherein thestructural frame comprises vertical corner posts, wherein the stud framepanel comprises a vertical corner post which is adjacent to and fixed toone of the vertical corner posts of the structural frame.
 8. A modularbuilding unit according to claim 1, wherein the building unit furthercomprises a plurality of beams extending transversely across the bottomof the structural frame and inwardly spaced from the ends of thestructural frame, each of the plurality of beams providing at least onefastener mounting hole or projection inwardly spaced from the sides ofthe structural frame for attachment to ground supports or anotherbuilding unit.
 9. A modular building unit according to claim 1, whereinthe building unit further comprises one or more removable verticalsupports on side faces of the structural frame, between corners of thestructural frame, and located underneath a removable weather resistantexternal panel, wherein the removable vertical supports and removableweather resistant external panel are temporary for removal aftertransport and before construction of the building, wherein the removableweather resistant external panel is positioned in-line with the externalface of the structural frame.
 10. A modular building unit according toclaim 1, wherein the building unit further comprises a furtherstructural panel immovably affixed to, but inwardly spaced from, a topface of the structural frame, wherein the top face is the uppermost faceof the structural frame.
 11. A modular building unit according to claim1, wherein the building unit comprises a portion of a pitched rooflocatable inside the modular building unit and able to be placed abovethe building unit to form part of a pitched roof of the building whenthe building unit is formed into a building.
 12. A method ofconstructing a building comprising providing a plurality of buildingunits as defined in claim 1, placing the building units next to oneanother and connecting the units together into a single structure.
 13. Abuilding comprising a plurality of modular building units according toclaim
 1. 14. A modular building unit for construction of a building,said modular building unit comprising a parallelepiped structural framesuitable for interconnection to another modular building unit inconstruction of the building, and a wall of the building unitcomprising: i) a first structural panel in line with structural elementsforming a parallelepiped shape of the parallelepiped structural frame soas to be substantially within the same plane as a face of theparallelepiped shape; wherein the first structural panel is fixed to theparallelepiped structural frame; and ii) a second structural panel thatis internal to and directly fastened to the parallelepiped structuralframe so as to be next to, parallel to and spaced from the firststructural panel so as to provide an air gap therebetween; wherein themodular building unit is transportable.